External electrical connectors for solar modules

ABSTRACT

Provided are low profile, water-resistant and touch safe safe electrical connectors for solar modules. According to various embodiments, the electrical connectors include a low-profile conductive stud, a low-profile sheath that surrounds the stud, and a socket to mate with the stud. According to various embodiments, the sheath and socket mate via keyed inter-engageable features. Also according to certain embodiments, the socket is fastened to the stud and/or sheath via snap fastening.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit under 35 U.S.C. §119(e) to the followingU.S. Provisional Patent Applications: Provisional Patent Application No.61/222,012, filed Jun. 30, 2009 and Provisional Patent Application No.61/238,164, filed Aug. 30, 2009. Both of these are incorporated byreference herein in their entireties.

BACKGROUND OF THE INVENTION

Photovoltaic cells arc widely used for generation of electricity, withmultiple photovoltaic cells interconnected in module assemblies. Suchmodules may in turn be arranged in arrays and integrated into buildingstructures or otherwise assembled to convert solar energy intoelectricity by the photovoltaic effect. An installation process for asolar module array involves connecting modules together at theinstallation site. A string of live modules connected in series iscapable of delivering several amperes of current at lethal voltages,i.e., greater than 300 V.

SUMMARY OF THE INVENTION

Provided are low profile, water-resistant and touch safe electricalconnector assemblies for solar modules. According to variousembodiments, the electrical connector assemblies include a low-profileconductive stud, a low-profile sheath that surrounds the stud, and asocket to mate with the stud. The socket is further connected to a cableor other connector for module interconnection. According to variousembodiments, the sheath and socket mate via keyed inter-engageablefeatures. Also according to certain embodiments, the electricalconnector assemblies are configured such that the socket is fastenableto the stud and/or sheath via snap fastening.

These and other aspects of the invention are described further belowwith reference to the figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a plan view of a solar-cell array including a plurality ofsolar-cell modules and centrally-mounted junction boxes in accordancewith various embodiments.

FIG. 1B is a perspective disconnected view of an electrical connectorassembly according to certain embodiments.

FIG. 2 shows the electrical connector assembly shown in FIG. 1B in anassembled configuration.

FIG. 3 is a perspective view of the sheath member depicted in FIGS. 1Band 2.

FIG. 4 is a perspective view of a sheath member that may be employed inaccordance with certain embodiments.

FIG. 5 is a perspective disconnected view of an electrical connectorassembly having a shroud-type sheath according to certain embodiments.

FIG. 6 is a cross-section view of the electrical connector assemblydepicted in FIG. 5 in an assembled configuration.

FIG. 7 is a perspective view of the sheath member depicted in FIGS. 5and 6.

FIG. 8 is a perspective disconnected view of a low profile electricalconnector assembly including a keyed low profile sheath and a keyedsocket member according to certain embodiments.

FIG. 9 is a perspective view of a keyed low profile sheath and studassembly disposed on a photovoltaic module according to certainembodiments.

FIG. 10 is a cross-sectional view of a low profile electrical connectorassembly including a keyed low profile sheath and a keyed socket memberin an assembled configuration according to certain embodiments.

FIG. 11 is a perspective view of a keyed low profile sheath according toone embodiment of the present invention.

FIG. 12 is an underneath view of a keyed socket according to oneembodiment of the present invention.

FIG. 13 is a perspective view of a keyed low profile sheath according toone embodiment of the present invention.

FIG. 14 is an underneath view of a keyed socket according to oneembodiment of the present invention.

FIG. 15 is a perspective disconnected view of an electrical connectorassembly including a circularly keyed low profile sheath and acircularly keyed socket according to certain embodiments.

FIG. 16 is a perspective view of a circularly keyed low profile sheathand conductive stud assembly disposed on a photovoltaic module accordingvarious embodiments.

FIG. 17 is a perspective view of a circularly keyed socket in accordancewith one embodiment of the present invention.

FIG. 18 is a perspective view of a circularly keyed low profile sheathin accordance with one embodiment of the present invention.

FIG. 19 is a cross-sectional view of an electrical connector assemblyincluding a circularly keyed low profile sheath mated with a circularlykeyed socket member in accordance with one embodiment of the presentinvention

FIG. 20 is a cross-sectional view of a circularly keyed low profilesheath and a mismatched circularly keyed socket disposed above thesheath.

FIG. 21 is a perspective view of a circularly keyed lockable socket inaccordance with certain embodiments

FIG. 22 is a perspective view of a circularly keyed sheath in accordancewith certain embodiments.

FIG. 23 is a cross-sectional view of an electrical connector assemblyincluding a circularly keyed low profile sheath and a circularly keyedlocked socket member in accordance with one embodiment of the presentinvention.

FIG. 24 is a perspective view of a circularly keyed lockable socket inaccordance with certain embodiments

FIG. 25 is a perspective view of a circularly keyed sheath in accordancewith certain embodiments.

FIG. 26 is a cross-sectional view of an electrical connector assemblyincluding a circularly keyed low profile sheath and a circularly keyedlocked socket member in accordance with one embodiment of the presentinvention:

FIG. 27 is a cross-sectional view of a circularly keyed low profilesheath and a mismatched circularly keyed lockable socket disposed abovethe sheath.

FIG. 28 is a cross-sectional view of a circularly keyed low profilesheath and a mismatched circularly keyed lockable socket disposed abovethe sheath.

FIG. 29 is a cross-sectional view of a portion of a solar module andelectrical connector assembly including an interior seal disposedbetween a conductive stud member and an encasing layer of the module.

DETAILED DESCRIPTION

Reference will now be made in detail to specific embodiments of theinvention. Examples of the specific embodiments are illustrated in theaccompanying drawings. While the invention will be described inconjunction with these specific embodiments, it will be understood thatit is not intended to limit the invention to such specific embodiments.On the contrary, it is intended to cover alternatives, modifications,and equivalents as may be included within the spirit and scope of theinvention. For example, while the description below refers chiefly toelectrical connector assemblies and the like for solar modules and solarmodule assemblies, they may be used with other electrical devices andassemblies. One of skill in the art will understand from the descriptionpresented herein how to implement the inventive electrical connectorsand related methods described herein with other types of devices andassemblies that include electrical connections. Also, in the followingdescription, numerous specific details are set forth in order to providea thorough understanding of the present invention. The present inventionmay be practiced without some or all of these specific details. In otherinstances, well known mechanical apparatuses and/or process operationshave not been described in detail in order not to unnecessarily obscurethe present invention.

Photovoltaic cells are widely used for generation of electricity, withmultiple photovoltaic cells interconnected in module assemblies. Suchmodules may in turn be arranged in arrays and integrated into buildingstructures or otherwise assembled to convert solar energy intoelectricity by the photovoltaic effect. However, a string of livemodules connected in series is capable of delivering several amperes ofcurrent at lethal voltages. During installation of solar module array,individual modules are interconnected. The present invention providesexternal electrical connector assemblies that enable safe and easyinstallation. According to various embodiments, the electrical connectorassemblies described herein have one or more of the following features:low profile, finger safe, keyed, lockable and easy to install (e.g.,without requiring installation tools and/or alignment).

Embodiments of the present invention relate to external electricalconnector assemblies for solar modules. According to variousembodiments, the external electrical connector assemblies describedherein provide a connection point for solar modules to an external grid,battery, etc. In certain embodiments, one or more external electricalconnector assemblies is associated with a solar module or panel in asolar panel array. An example of solar modules interconnected viaexternal connector assemblies is shown in FIG. 1A. FIG. 1A shows a planview 100 of a solar module array 152 including a plurality 160 of solarmodules 160 a, 160 b and 160 c. Each module includes a set ofinterconnected solar cells 140. The cells may be any type ofphotovoltaic cells, including but not limited to CIS, CIGS, CdTe orsilicon photovoltaic cells. The plurality 160 of solar-cell modules 160a, 160 b and 160 c are interconnected via external connector assembliesmounted on the modules and connected to in-laminate-diode assemblies.For example, solar-cell module 160 b includes a first in-laminate-diodeassembly 170, a second in-laminate-diode assembly 171 and a thirdin-laminate-diode assembly 172; solar module 160 b also includes a firstbusbar 174 and a terminating busbar 176 each electrically coupled withthe first, second and third in-laminate-diode assemblies 170, 171 and172. Although the figure depicts a specific in-laminate configuration ofinterconnected solar cells in which the cells are arranged in threerows, including in-laminate diode assemblies, etc., the invention is notlimited to any particular arrangement of interconnected cells within themodule, but may be used with any appropriate arrangement. Othervariations are also within the scope of the invention.

The solar module 160 b further includes first and second electricalconnector assemblies 180 b and 182 b, mounted on the glass or otherprotective structure of the module. The first and second electricalconnector assemblies 180 b and 182 b are configured to enable currentcollection from interconnected solar cells of the module 160 b and toallow interconnection with at least one other external device, in thiscase module 160 a for electrical connector assembly 180 b, and module160 c for electrical connector assembly 182 b. In embodiments of thepresent invention, the module 160 b is coupled in series with modules160 a and 160 c. Solar module 160 a similarly includes externalelectrical connector assemblies 180 a and 182 a and solar module 160 csimilarly includes external electrical connector assemblies 180 c and182 c. Solar modules 160 a and 160 b are intercoupled withinterconnector 184 and solar modules 160 b and 160 c are intercoupledwith interconnector 188. According to various embodiments, the modulesmay be connected in series, parallel, series-parallel, etc. The solarpanel array may be mounted on a roof or other surface to absorb solarenergy and convert it to electricity.

The modules and solar array described above is an example of solarmodule, electrical connector and array assemblies within the scope ofthe invention. The placement of the electrical connector assemblies maybe varied appropriate on the module—at its center, edge, etc. Cellwiring schemes, including the presence, absence, number or arrangementof busbars and diodes may also be varied as appropriate. The shape ofelectrical connector assemblies according to embodiments of theinvention may be varied as appropriate. As discussed further below, incertain embodiments, the electrical connector assemblies or componentsthereof have a generally circular shape to facilitate installation.

As used herein, the term “electrical connector assembly” refers to atleast one lead or other conductive element configured to provide aconductive pathway, typically between the cells or internal circuitry ofa solar module and one or more external cables or devices. In manyembodiments, there are two such electrical connector assemblies permodule, one providing a positive lead and one providing a negative lead.The electrical connector assemblies described herein may also bereferred to as electrical connection boxes or junction boxes. In certainembodiments, the electrical connector assemblies described hereineliminate the need for junction boxes housing both positive and negativeleads.

In certain embodiments, the electrical connector assemblies describedherein include a conductive element, such as a conductive stud or pin,that is in electrical communication with the interconnected solar cells,and that extends from the interior of the module to the exterior of themodule. The electrical connector assemblies may further include a sheathsurrounding the conductive element, and a socket including a conductiveportion to mate with the stud. In certain embodiments, the socket isconfigured to engage with the sheath. The electrical connectorassemblies may further include a connector attached to or connectable tothe socket for interconnection to other modules, etc. According tovarious embodiments, the connector assemblies may be in assembled orunassembled configurations.

According to various embodiments, the electrical connector assembliesdescribed have a low profile, as measured as the greatest distance theyextend above a module. Low profile assemblies facilitate low-costmanufacturing and provide less interference on the exterior of themodule, making the module more stackable when compared to modules withhigh profile electrical connector assemblies. According to variousembodiments, the profile is no more than about 2 inches, 1.9 inches, 1.8inches, 1.7 inches, 1.6 inches, 1.5 inches, 1.4 inches, 1.3 inches, 1.2inches, 1 inch, 0.9 inches, 0.8 inches, 0.7 inches, 0.6 inches, 0.5inches, 0.4 inches, 0.3 inches, 0.2 inches or 0.1 inches.

In many embodiments, the stud of the low profile connector assemblies isshort and squat. In conventional connectors, the conductive pin is longand narrow to reduce contact resistance. In certain embodiments, thestuds described herein are squat forms, such as cylinders, with thecontact primarily around their girths, rather along their lengths. Theconductive element may extend above the module surface a distance of nomore than about 1.5 inches, 1.4 inches, 1.3 inches, 1.2 inches, 1 inch,0.9 inches, 0.8 inches, 0.7 inches, 0.6 inches, 0.5 inches, 0.4 inches,0.3 inches, 0.2 inches or 0.1 inches.

In accordance with various embodiments, studs are provided including aninsulative portion disposed on top of a conductive portion of the stud.When a sheath of the present invention is disposed around such a stud ofa photovoltaic module, the non-conductive sheath has no opening sized toallow a finger to touch a conductive portion of the stud.

The connector assemblies described herein are finger-safe. As usedherein, the term “finger-safe” refers to an assembly including aconductive element and sheath surrounding the conductive element suchthat there is no manner in which a finger-shaped object having adiameter of about 4 mm or larger can contact the conductive portion ofthe conductive element. In certain embodiments, finger-safe refers tothe finger-safer requirements specified in Underwriters Laboratorypublication UL-1703, Jun. 30, 2004, which is incorporated by referenceherein.

In transport, solar modules are unconnected and require interconnectionduring installation. According to various embodiments, a solar module isprovided to an installer with a conductive element and sheath mounted onthe module. Interconnecting solar modules and/or connecting a solarmodule to an external battery, grid or other device, involves engaging asocket as described herein with the conductive element and sheathdisposed on the module. The electrical connector assemblies describedherein are finger-safe prior to, during and after such installation. Aninstaller cannot contact any conductive part of the conductive elementduring installation.

In certain embodiments, the electrical connection assemblies are keyed.As used herein, the term “keyed” refers to having one or mechanicalfeatures that prevents connection to an incorrect component of the sametype. As an example, in certain embodiments, the components of theelectrical connector assemblies described herein are keyed, such that apositive lead from a module may be connected only to a negative socketand vice-versa. In certain embodiments, the electrical connectorassemblies are lockable, such that once connected, they cannot beunconnected without the use of a tool.

In certain embodiments, the electrical connector assemblies have one ormore features to facilitation easy installation. For example, in certainembodiments, the electrical connector assemblies do not require the useof a tool for installation but may be fit together, e.g., by snapping asocket onto a sheath and/or conductive elements. Also in certainembodiments, the electrical connectors do not require alignment prior toconnection, but may be connected at any radial angle. For example, incertain embodiments, the electrical connector assemblies include acircularly keyed sheath member and a circularly keyed socket member.Once the keyed portions of each member are facing each other, the sheathand socket members can be fastened together at any relative radial angledue to the circular symmetry of the keyed inter-engageable features.

According to various embodiments, assembly of the socket member to thestud and/or sheath members includes snap fastening. In certainembodiments, one member includes an insertion component and anothermember includes a receiving component configured to fit around theinsertion member and defining an insertion component receiving area. Incertain embodiments, in its unassembled state the electrical connectorassembly includes an insertion component having a diameter (or otherlength dimension in the case of non-cylindrical components) slightlylarger than a diameter of the receiving member. In certain embodiments,one or both of the insertion component and the receiving component mayinclude a feature such that the insertion component has a diameterslightly smaller than a diameter of the receiving component. Forexample, according to various embodiments, the insertion component maybe flared slightly, with the flared portion of the insertion componenthaving a larger area than the corresponding receiving area; theinsertion component may have a ridge or one or more protrusions aroundits girth, with the diameter of the insertion component including theridged or protruding portions larger than that of the receiving area;etc. According to various embodiments, the receiving component includesa narrowed portion and/or a ridge or one or more protrusions within thereceiving area, or other features that narrow the receiving area so thatit has a smaller diameter than the insertion component. Assembling theinterconnect assembly may involve disposing the socket member over thesheath and/or stud members disposed on the module and applying adownward force on the socket member. This force causes one or more ofthe insertion component and the receiving components to flex or bendslightly, thereby allowing the receiving component to fit around theinsertion component, and the insertion component to be inserted into thereceiving area. According to various embodiments, the insertioncomponent and/or the receiving component may be resilient such thatafter fitting, it partially or fully reverts to its original form.Various examples are presented in the below description. As indicated,the socket member may fit onto one or both of the stud (also referred toas conductive element) member and the sheath member in this fashion. Inembodiments wherein the socket member engages with the stud member inthis fashion, typically, though not necessarily, it is the stud thatincludes the insertion component, and the socket the receiving area. Incertain embodiments, the sockets of the electrical connectors describedherein are lockably engageable with a sheath and/or stud assembly.

In certain embodiments, once assembled, the electrical connectorassemblies described herein, including conductive element member (alsoreferred to as stud member or stud assembly), socket member and sheathmember, contain substantially no air gaps. Also according to certainembodiments, the electrical connector assemblies include a sealsurrounding a portion of the stud on the interior of the module.

Examples of electrical connector assemblies according to variousembodiments are described below. FIGS. 1B-3 show various components ofan electrical connector assembly according to certain embodiments, inwhich a non-conductive housing disposed over a conductive stud of asolar module has no opening sized to allow a finger to touch the stud.In certain embodiments, the housing is configured to allow detachment ofa socket from the stud without subjecting a person who is performing thedetachment to the risk of contact with the stud.

First, FIG. 1B is a perspective disconnected view of the electricalconnector assembly, also referred to as a junction box, including ahousing 101, a horizontal connector 103, and a stud 102 disposed on aphotovoltaic module 104. Module 104 includes interconnected solar cells(not shown) and other in-laminate components, encased by top and bottomencasing layers, the top one of which is a light transparent layer madeof a material including but not limited to glass, plastic, orfiberglass. The bottom encasing layer may be made from a material suchas glass, plastic, metal, or fiberglass. Stud 102 is a conductivematerial, typically a metal, and provides an electrical connection tothe interconnected solar cells (not shown) within photovoltaic module104.

In this embodiment, the stud 102 includes a circular base portion 102 aand a cylindrical portion 102 b. Base portion 102 a is within the moduleglass. Socket member 103 includes a circular base portion 103 a and avertical nubbin 103 b, which allows it to be fitted onto stud 102sheathed by housing 101. Socket member 103 further includes attachedhorizontal connector 103 c, which provides a conductive pathway fromstud 102 to another module, battery, grid, etc. Socket member 103 mayalso include tool interface feature 103 d for removal.

The module is delivered with housing 101, also referred to as a sheath,mounted on the module 104 disposed around the stud 102. Thus, even whensocket member 103 including horizontal connector 103 c is disconnectedfrom the stud. 102, the housing 101 shields the stud 102 preventinghuman contact with the stud 102.

FIG. 2 shows the electrical connector assembly after connection. In itsunconnected state, housing 101 is disposed on module 104, disposedaround stud (not shown), which is in electrical communication with thecells of the solar module. To connect the horizontal connector 103 c tostud 102, the socket member is inserted into an opening of housing 101,with the opening having a middle wide portion 101 a, a top narrowportion 101 b and a bottom narrow portion 101 c. Circular base portion103 a of the socket member is inserted via a wide portion 101 a of theopening and vertical nubbin 103 b of the socket member is inserted via anarrow portion 101 b of the opening. The socket member is then pressedonto the stud, with horizontal connector 103 c extending through narrowopening portion 101 c of the housing.

In certain embodiments, socket portion 103 b may be fastened tocylindrical portion 102 b via snap fastening. For example cylindricalportion 102 b of stud 102 may be flared slightly at the end distal tothe circular base portion 102 a. Socket member 103 may include a hollowportion (not shown) slightly smaller than the flared portion ofcylindrical portion 102 b. On application of pressure to the verticalnubbin 103 b, the socket member 103 is forced over the flaredcylindrical portion 102 b, fitting snugly into place.

In many embodiments, the socket member 103 including horizontalconnector 103 c can be installed without the use of a tool, but byapplication of pressure on the socket member 103 after it is insertedinto housing 101. In certain embodiments, an installer may do this bypressing the socket member 103 with a hand. Once connected, however, theelectrical connector assembly is configured to prevent easy removal. Incertain embodiments, a tool is necessary for removal, e.g., by pryingthe socket member 103 off the stud 102. In the embodiment depicted inFIGS. 1B and 2, both housing 101 and socket member 103 have toolinterface features 101 d and 103 d, respectively, allowing safeengagement with such a tool.

FIG. 3 is a perspective view of the housing 101, also referred to as asheath, depicted in FIGS. 1B and 2. The housing 101 has an outer wall302 including a round portion 312 and two opposing substantially flatportions 313, the two opposing substantially flat portions terminatingat a front face 305. As described above, the front face 305 includes afront face opening 306 sized to allow a horizontal connector to enterthe housing 101 and engage with a stud (102 in FIG. 1 B) whilesubstantially preventing a finger from touching the stud. The front face305 further includes two opposing portions 311 extending inward andsized to allow a horizontal connector 103 to enter the front faceopening 306 and engage with a stud. The housing 101 further includes abase portion 303 having a base opening 308. The base portion 303includes panels 309 that form a tool opening 310 (tool interface feature101 d in FIG. 1) configured to allow a tool to enter to disconnect ahorizontal connector. As described above with respect to FIGS. 1B and 2,the base opening 308 is sized to surround a socket member 103 includinghorizontal connector 103 c connected to a stud 102 and is incommunication with the front face opening 306. The housing 101 furtherincludes a ceiling portion 304 having a ceiling opening 307 incommunication with the front face opening 306. As described above,ceiling opening 307 is sized to allow a horizontal connector 103including a vertical nubbin to enter through the front face opening 306.

FIG. 4 shows a housing 101 according to an alternative embodiment, inwhich a ceiling opening 407 is defined by the ceiling portion 304 andsized to allow a tool to enter to press down on a socket member toconnect a horizontal connector to a stud. In this embodiment, a socketmember would not need a vertical nubbin, such as nubbin 103 b shown inFIG. 1B, as a tool entering via opening 407 could press down on a basemember such as 103 b of socket member 103 shown in FIG. 1B.

FIGS. 5-7 shows an electrical connector assembly having a shroud typehousing according to another embodiment. First, FIG. 5 is a perspectivedisconnected view of a shroud-type housing 501, stud 102 and verticalsocket member 503 including a vertical connector disposed on module 104.FIG. 6 is a cross-sectional view of a junction box with verticalconnector 503 electrically connected to stud 102. When verticalconnector 503 is disconnected from stud 102, shroud-type housing 501sheaths stud 102, preventing human contact with stud 102.

FIG. 7 is a perspective view of a shroud-type housing 501. Theshroud-type housing 501 includes a side wall 702 and a base 705. Thebase 705 has a base opening 706 sized to surround a socket connected toa stud 102. The side wall 702 has a substantially uniform thickness fromthe base 705 to the rim 704 formed by the top of the side wall 702. Thediameter of the portion of the side wall 702 that connects to the base705 is larger than the diameter of rim 704. The rim 704 has a rimopening 707 sized to allow a socket member 503 to engage therein.

Returning to FIG. 6, socket member 503 includes conductive portion 503 athat is mated with stud 102 to provide an electrical connection tovertical connector 503 c. In certain embodiments, socket member 503 maybe mated with stud 102 via snap fastening. For example cylindricalportion 102 b of stud 102 may be flared slightly at the end distal tothe circular base portion 102 a. The hollow portion of socket member 503to be fit around stud 102 is smaller than the flared portion of circularbase portion 102 a. On application of pressure to the socket member 503,it is forced over the flared cylindrical portion 102 b, fitting snuglyinto place. Once connected, the electrical connector assembly generallyrequires a tool for disassembly. As with the electrical connectorassemblies described with reference to FIGS. 1B-4, the module isgenerally delivered with stud 102 connected to the solar cells withinthe module protective layers, and shroud 501 glued or otherwise affixedto the glass or other protective layer to thereby prevent human contactwith the stud 102.

As indicated above, in certain embodiments, the stud members are flaredat the top, allowing the socket members to snap into place uponapplication of force. As force is applied, the stud and/or socket membermaterial flexes or bends sufficiently to allow the socket member to fitover the stud. In certain embodiments, the material is resilient suchthat it flexes or expands back once the components are mated. In certainembodiments, the socket members described above may have a lip orprotrusions extending inward from hollow portion of the socket, creatinga smaller diameter at the rim or protrusions. In these embodiments, thestud may or may not be flared as described above.

In certain embodiments, a stud of an electrical connector assemblyincludes insulation disposed thereon. In certain embodiments, thisfeature allows a low profile sheath to be used. For example, in certainembodiments, a sheath is approximately the height of the stud. Also, incertain embodiments, sheaths having features configured to engage with aportion of a socket member are provided. Furthermore, in certainembodiments, a sheath is keyed to allow only a mated socket to beengaged thereon. For instance, a first embodiment of a junction boxsheath could be keyed with a first key configuration that would onlyallow a socket to be engaged thereon, wherein this first keyedconfiguration would only be disposed on positively charged connectors.Furthermore, a junction box sheath with a second key configuration whichwould only allow a mated socket to be engaged thereon could be employedon only negatively charged connectors. The use of differentiatedconfigurations as described above could substantially prevent crossconnection of electrical connectors, thus preventing shorting of thesystem or module.

FIG. 8 is a perspective disconnected view of a keyed low profile sheath801, a conductive stud 802 including base conductive portion 807 a,cylindrical conductive portion 807 b, and insulated top portion 806, anda keyed socket member 803. Keyed socket member 803 is configured toengage with the keyed low profile sheath 801 and further connected to ahorizontal connector 804. In use, stud 802 is mounted on a solar modulesurrounded by sheath 801, which is glued or otherwise affixed to themodule. Sheath 801 includes at least one feature that allows only asocket 803 having corresponding features to be connected to stud 802.Here, sheath 801 includes a base portion 801 a and a raised rim 801 bhaving indent 801 c. Assembled, raised rim 801 b surrounds at least theconductive portion of the stud 802. Indent 801 c is configured to engagea corresponding tab feature on socket 803. It prevents sockets havingunaligned tab features from connecting to stud 802. The inner diameterof raised rim 801 b is sized to allow a hollow conductive portion (notshown) of socket member 803 to fit between the raised rim 801 b and stud802, with the gap between the raised rim 801 b and stud 802 small enoughto prevent a human finger from contacting the conductive portions 807 aand 807 b of stud 802 when the socket is not in place. In certainembodiments, the outer diameter of rim 801 b is sized to fit onlysockets having a corresponding groove and preventing sockets havinggrooves of different diameters from connecting to stud 802.

FIG. 9 is a perspective view of a keyed low profile sheath 901 and studassembly 902 disposed on a photovoltaic module 905. The keyed lowprofile sheath 901 provides protection around the exterior of the studassembly 902 while the insulator portion 906 of the stud assembly 902provides protection on the top portion of the stud assembly 902. Asshown, the conductive portion 907 of the stud assembly 902 is notaccessible to human contact, significantly reducing the risk of electricshock when modules are installed or when they undergo maintenance.

FIG. 10 is a cross-sectional view of a keyed electrical connectorassembly according to certain embodiments, including keyed low profilesheath 1001 and stud assembly 1002 disposed on a photovoltaic module1005 and a keyed socket 1003 disposed on and electrically connected tostud assembly 1002 and engaged on the keyed low profile sheath 1001. Thekeyed socket 1003 is further connected to a horizontal connector 1004and includes a stud engaging portion 1008. Stud engaging portion 1008includes an electrically conductive portion 1008, which is electricallyintegrated with the conductive portion 1007 of the stud assembly 1002.Stud assembly 1002 also includes insulative portion 1006. In certainembodiments, socket member 1003 mates with stud assembly 1002 via snapfastening. The portion of stud 1002 distal to the module 1005 may beflared, and have a slightly larger diameter than that of the hollowportion of socket member 1003, the sidewalls of which are defined bystud engaging portion 1008. When a downward force is applied to socketmember 1003, the engaging portion 1008 bends or flexes sufficiently suchthat it fits snugly into the space between cylindrical portion 1007 ofstud 1002 and the inner diameter of sheath 1001. Once connected, aconductive pathway from stud 1002 to horizontal connector 1004 isestablished via the conductive portion 1009 of stud engaging portion1008 of socket member 1003.

FIG. 11 is a perspective view of a keyed low profile sheath 1101according to one embodiment of the present invention. The keyed lowprofile sheath 1101 has a support portion 1110 having a first diameterand a torso portion 1111 that has a base 1112 with a second diameter andceiling 1113 with a third diameter. The diameter of the base 1112 of thetorso portion 1111 is smaller than the diameter of the support portion1110. The diameter of the ceiling 1113 of the torso portion 1111 issmaller than the diameter of the base 1112 of the torso portion 1111.The torso portion 1111 further includes a keyed portion 1114 thatincludes two slots 1115 configured to engage a keyed portion of a keyedsocket (see keyed portion 1216 of keyed socket 1203 in FIG. 12). The lowprofile sheath 1101 further includes a center opening 1116 configured tosurround a stud assembly and accommodate an engaging portion of a keyedsocket (see engaging portion 1208 of socket 1203 in FIG. 12).

FIG. 12 is an underneath view of a keyed socket 1203 connected to ahorizontal connector 1204. Keyed socket 1203 is configured to be matedwith a keyed low profile sheath consistent with the embodiment shown inFIG. 11. The keyed portion 1216 of the keyed socket 1203 includes twoprongs 1217 that are configured to fit into two slots 1115 disposed onthe keyed low profile sheath 1101 shown in FIG. 11. Keyed socket 1203also includes stud engaging portion 1208 including conductive portion1209. A recess 1216 is configured to receive a stud.

FIG. 13 is a perspective view of a keyed low profile sheath 1301 showinganother example of a sheath according to certain embodiments. The keyedlow profile sheath 1301 is similar to the keyed low profile sheath 1101of FIG. 11, with the exception that the keyed portion 1318 includes asingle slot 1319 configured to engage a keyed portion 1420 of a socket1403 (see FIG. 14).

FIG. 14 is an underneath view of a keyed socket 1404 connected to ahorizontal connecter 1404. The keyed socket 1403 is configured to bemated with a keyed low profile sheath 1301 consistent with theembodiment shown in FIG. 13. The keyed portion 1420 of the keyed socket1403 includes one prong 1421 that is configured to fit into the slot1319 disposed on the low profile sheath 1301 shown in FIG. 13.

The keyed socket 1403 shown in FIG. 14 would not be able to engage onthe keyed low profile sheath 1101 shown in FIG. 11 as the prong 1421would not be able to fit into either of the two slots 1115 of the keyedlow profile sheath 1101. Similarly, the keyed socket 1203 shown in FIG.12 would not be able to engage on the keyed low profile sheath 1301shown in FIG. 13 as the two prongs are spaced too far apart to be ableto fit into the slot 1319 of the keyed low profile sheath 1301.

In practice, keyed low profile sheaths and their mated sockets may beused to distinguish positive and negative connectors to decrease thelikelihood of cross connection. It should be noted that slot features1115 and 1318 may be on a socket members with prong features 1217 and1421 on sheath members. Moreover, the keyed features are not limited toslots and corresponding prongs, but may be any type of inter-engageablekeyed features. As discussed further below, in certain embodiments,circular keyed features that do not require rotational alignment areprovided.

FIG. 15 is a perspective, disconnected view of a circularly keyed lowprofile sheath 1501, a conductive stud assembly 1502 includinginsulating top portion 1506 connected to solar cells within photovoltaicmodule 1505, and a circularly keyed socket 1503 configured to be matedwith the circularly keyed low profile sheath 1501. The circularly keyedsocket is further connected to a horizontal connector 1504. FIG. 16 is aperspective view of certain assembled components of an electricalconnector assembly including a circularly keyed low profile sheath 1501and conductive stud assembly including conductive portion 1507 andinsulative portion 1506, disposed on a photovoltaic module 1505.According to certain embodiments, the module 1502 is shipped as shown,with sheath 1501 affixed to the module surface and surrounding studassembly 1502. The circularly keyed low profile sheath 1501 providesprotection around the exterior of the conductive stud assembly 1502while the insulating top portion 1506 of the conductive stud assembly1502 provides protection on the top portion of the conductive studassembly. As shown, the conductive portion 1507 of the conductive studassembly is not accessible to human contact, significantly reducing therisk of electric shock when installing or maintaining photovoltaicmodules.

FIG. 17 is a perspective view of a circularly keyed socket 1703 (shownsheath- and stud-engaging side up) in accordance with one embodiment ofthe present invention. The socket 1703 is further connected to ahorizontal connector 1704. Circularly keyed socket 1703 is configured tobe mated with a circularly keyed low profile sheath 1801 (shown in FIG.18). Socket 1703 is circularly keyed, that is the keyed portion 1710disposed on the base portion 1711 includes a circular protruding shapethat is configured to fit in a circular groove 1812 (FIG. 18) disposedon the circularly keyed low profile sheath 1801 (FIG. 18). In thedepicted in embodiment, there are no other keyed features such as slotsor prongs on socket 1703; as a result, fitting socket 1703 to sheath1801 depicted in FIG. 18 does not require any rotational alignment ofkeyed features. Rather, once socket 1703 is centered over sheath 1801,it may connected at any rotational angle. Circularly keyed socket 1703further includes a stud engaging portion 1708 including an electricallyconductive portion 1709 which is configured to be electricallyintegrated with a conductive portion of a conductive stud assembly.

FIG. 18 is a perspective view of a circularly keyed low profile sheath1801 according to one embodiment of the present invention. The keyed lowprofile sheath 1801 is configured to be mated with a circularly keyedlow profile socket 1703 as shown in FIG. 17. The circularly keyed lowprofile sheath 1801 has a base portion 1813 and a circular grooveportion 1812 configured to engage a keyed portion 1810 of the circularlykeyed socket 1703 in FIG. 17. The circularly keyed low profile sheath1801 further includes a center opening 1814 configured to surround aconductive stud assembly (1902 in FIG. 19) and engage the portion 1708of the circularly keyed socket 1703.

FIG. 19 is a cross-sectional view of an electrical connector assemblyincluding a circularly keyed low profile sheath 1801 and a conductivestud 1902 disposed on a photovoltaic module 1905. A circularly keyedsocket 1703 is engaged with circularly keyed low profile sheath 1801 andconductive stud 1902 and further connected to a horizontal connector1704, thereby electrically connecting conductive stud 1902 andhorizontal connector 1704. Stud assembly 1902 includes insulativeportion 1906 disposed on top of the conductive portion 1907 of the studassembly 1902. The keyed socket 1703 is engaged on the conductive studassembly 1902 through the stud engaging portion 1708. As shown, thekeyed portion 1710 of the circularly keyed socket 1703 fits into thecircular groove portion 1812 of the circularly keyed low profile sheath1801 allowing the stud engaging portion 1708 of the circularly keyedsocket 1703 to engage with the conductive stud assembly 1902. In certainembodiments, stud engaging portion 1708 of socket 1703 engages with stud1902 via snap fastening as described above, with stud 1902 the insertioncomponent, stud engaging member 1708 (including conductive portion 1709)the receiving component and the hollow cylindrical area defined by studengaging member 1708 (including conductive portion 1709) and baseportion 1711 the receiving area. As shown in the cross-sectional view inFIG. 19, the assembled electrical connector assembly contains no airgaps inside the assembly. This may be advantageous as provides anelectrical connector assembly that does not have any spaces in whichcondensation can form and that does not require electrically insulativepotting material to be placed in air gaps.

FIG. 20 is a cross-sectional view of a circularly keyed low profilesheath 2001 and a mismatched circularly keyed socket 2003 disposed abovethe sheath 2001. Because keyed feature (circular protrusion) 2015 onsocket 2003 and keyed feature (circular groove) 2012 on sheath 2001 arenot configured to inter-engage, having different diameters, studengaging portion 2008 of socket 2003 is prevented from engaging stud2002. In certain embodiments, the conductive portion 2009 of studengaging portion 2008 is prevented from contacting the conductiveportion 2007 of stud 2002. As described above, keyed low profile sheathsand their mated snap fastener sockets as described above could be usedto distinguish positive and negative connectors to decrease thelikelihood of cross connection.

In certain embodiments, the keyed socket may be configured to belockably engageable with a keyed low profile sheath in order to provideadditional security to the electrical connections. FIG. 21 is aperspective view of a circularly keyed lockable socket 2103 inaccordance with certain embodiments. Circularly keyed lockable socket2103 is configured to be mated with circularly keyed lockable lowprofile sheath 2201 (shown in FIG. 22). Circularly keyed lockable socket2103 includes a stud engaging portion 2108 including an electricallyconductive portion 2109 which is configured to be electricallyintegrated with a conductive portion 2307 (shown in FIG. 23) of aconductive stud assembly. Socket 2103 includes a keyed portion disposedon a base portion 2123 of the circularly keyed lockable socket 2103. Thekeyed portion 2122 includes a circular ridge having a first diameterthat is the same as the outer diameter of the stud engaging portion 2108and a second diameter that is larger than the outer diameter of the studengaging portion 2108. The keyed portion 2122 is configured to fit intoa circular opening 2227 defined by circular ridge 2225 of circularlykeyed lockable low profile sheath 2201 (shown in FIG. 22). Circularlykeyed lockable socket 2103 further includes rimmed locking portions 2120configured to engage with ridged lock accepting portions 2224 ofcircularly keyed lockable low profile sheath 2201 (shown in FIG. 22).Circularly keyed lockable socket 2103 further includes supporting ridges2121 that are in a circumferential line with the rimmed locking portions2120.

FIG. 22 is a perspective view of a circularly keyed lockable low profilesheath 2201 in accordance with one embodiment of the present invention.The circularly keyed lockable low profile sheath 2201 is configured tobe mated with circularly keyed lockable socket 2103 shown in FIG. 21.Circularly keyed lockable low profile sheath 2201 has an annular baseportion 2223 and a circular ridge 2225 that defines a center opening2227 in sheath 2201. The center opening 2227 is configured to engage akeyed portion 2122 of circularly keyed lockable socket 2103 shown inFIG. 21. The circularly keyed lockable low profile sheath 2201 isfurther configured to surround a conductive stud assembly 2301 (shown inFIG. 23) to provide a barrier to decrease risk of electrical shock. Thecircularly keyed lockable low profile sheath 2201 further comprisesridged lock accepting portions 2224 that are configured to engage rimmedlocking portions 2120 of the circularly keyed lockable socket 2103 shownin FIG. 21. Ridged lock accepting portions 2224 are separated by a gap2230 in this embodiment to allow a tool to engage and disconnect thesocket 2103.

Socket 2103 may be fastened during assembly to sheath 2201 via snapfastening. In this example, rimmed locking portions 2120 are insertedinto an annular receiving area defined by ridged locked acceptingportions 2224, annular base portion 2223 and circular ridge 2225. Priorto fastening, the outer diameter of rimmed locking portions 2120 islarger the outer diameter of this receiving area. During assembly, aforce is applied to socket 2103, causing rimmed locking portions 2120 toflex and slip past ridged locked accepting portions 2224. Rimmed lockingportions 2120 then flex back into position, snapping into place lockedinto place under ridged lock accepting portions 2224.

FIG. 23 is a cross-sectional view of an assembled electrical connectorassembly including circularly keyed socket 2103 (as depicted in FIG.21), circularly keyed lockable low profile sheath 2201 (as depicted inFIG. 22) disposed on a photovoltaic module 2305 with a stud assemblyincluding conductive portion 2307 extending from the interior of module2305. The shaded areas in FIG. 23 are included for clarity and areintended to show open spacing in the assembly. Stud engaging portion2019 and base portion 2123 of socket 2103 define a hollow area in whichthe stud is received. Circularly keyed lockable socket 2103 is engagedwith the conductive portion 2307 of the stud assembly through theconductive portion 2109 of stud engaging portion 2108 and is alsoengaged with the circularly keyed lockable low profile sheath 2201through keyed portion 2122. As shown in FIG. 23, rimmed locking portions2120 of the circularly keyed lockable socket 2103 are engaged with theridged lock accepting portions 2224 of circularly keyed lockable lowprofile sheath 2201. The engagement of the rimmed locking portions 2120of the of the circularly keyed lockable socket 2103 with the ridged lockaccepting portions 2224 of circularly keyed lockable low profile sheath2201 provides a locking mechanism that renders removal of the circularlykeyed lockable socket 2103 impossible or extremely difficult without theuse of a removing tool.

FIG. 24 is a perspective view of a circularly keyed lockable socket 2403in accordance with an alternative embodiment of the present invention.Circularly keyed lockable socket 2403 is configured to be mated with acircularly keyed lockable low profile sheath 2501 (shown in FIG. 25).Circularly keyed lockable socket 2403 includes a stud engaging portion2408 including an electrically conductive portion 2409 which isconfigured to be integrated with a conductive portion of a conductivestud assembly. Circularly keyed lockable socket 2403 includes a keyedportion 2427 disposed on a base portion 2423, the keyed portionincluding a circular protruding ridge having a first diameter that islarger that the outer diameter of the stud engaging portion 2408 and asecond diameter that is larger than the first diameter of the keyedportion 2427. The keyed portion 2427 is configured to fit around acircular ridge 2529 of the circularly keyed lockable low profile sheath2501 show in FIG. 25. Circularly keyed lockable socket 2403 furtherincludes rimmed locking portions 2420 configured to engage with ridgedlock accepting portions 2524 of circularly keyed lockable low profilesheath 2501 (FIG. 25). Circularly keyed lockable socket 2403 furtherincludes supporting ridges 2421 that are in circumferential line withthe rimmed locking portions 2420.

FIG. 25 is a perspective view of a circularly keyed lockable low profilesheath 2501 in accordance with embodiments of the present invention. Thecircularly keyed lockable low profile sheath 2501 is configured to bemated with circularly keyed lockable socket 2403 (FIG. 24). Circularlykeyed lockable low profile sheath 2501 has an annular base portion 2523and a circular ridge 2529 that defines a center opening 2530 in thecenter of the sheath 2501. The center opening 2530 is configured toaccept a stud engaging portion 2408 of the circularly keyed lockablesocket 2403 and to surround a conductive stud assembly of a photovoltaicmodule in order to provide a barrier to decrease risk of electricalshock. The circularly keyed lockable low profile sheath 2501 furtherincludes ridged lock accepting portions 2524 that are configured toengage rimmed locking portions 2420 of the circularly keyed lockablesocket 2403. As with the socket and sheath members described in FIGS.21-23, the socket 2403 is fastened to sheath 2501 via snap fastening.

FIG. 26 is a cross-sectional view of an electrical connector assemblyincluding a circularly keyed lockable low profile sheath 2501 and a studassembly including conductive portion 2607 disposed on a photovoltaicmodule 2605. The shaded areas in FIG. 26 are included for clarity andare intended to show open spacing in the assembly. A circularly keyedlockable socket 2403 is engaged with the conductive stud assemblyportion 2607 through stud engaging portion 2408 and is also engaged withthe circularly keyed lockable low profile sheath 2501 through keyedportion 2427. As shown in FIG. 26, when the circularly keyed lockablelow profile sheath 2501 and the circularly keyed lockable socket 2403are engaged with one another, the circular ridge 2529 of the circularlykeyed lockable low profile sheath 2501 fits between the keyed portion2427 and the portion 2408 of the circularly keyed socket 2403. Also asshown in FIG. 26, rimmed locking portions 2420 of the circularly keyedlockable socket 2403 are engaged with the ridged lock accepting portions2524 of circularly keyed lockable low profile sheath 2501. Theengagement of the rimmed locking portions 2420 of the of the circularlykeyed lockable socket 2403 with the ridged lock accepting portions 2524of circularly keyed lockable low profile sheath 2501 provides a lockingmechanism that renders removal of the circularly keyed lockable socket2403 impossible or extremely difficult without the use of a removingtool.

The circularly keyed lockable sockets 2103 and 2403 (shown in FIGS. 21and 24, respectively) and the circularly keyed low profile sheaths 2201and 2501 (shown in FIGS. 22 and 25, respectively) are keyed such thatmismatched pairings are not be able to engage with one another. FIG. 27is a cross-sectional view of a circularly keyed lockable low profilesheath 2201 in accordance with that shown in FIG. 22 disposed on aphotovoltaic module. A mismatched circularly keyed lockable socket 2403in accordance with that shown in FIG. 24 is disposed above the sheath2201. FIG. 27 illustrates that the keyed portion 2427 of the circularlykeyed lockable socket 2403 collides with the circular ridge 2225 of themismatched circularly keyed lockable low profile sheath 2201 ifengagement of these two components is attempted, preventing theconnection of the mismatched components. In certain embodiments, theconductive portions of socket 2403 and stud 2702 are preventing fromcontacting.

Similarly, FIG. 28 is a cross-sectional view of a circularly keyedlockable low profile sheath 2501 in accordance with that shown in FIG.25 disposed on a photovoltaic module. A mismatched circularly keyedlockable socket 2103 in accordance with that shown in FIG. 21 isdisposed above the sheath 2501. FIG. 28 illustrates that the keyedportion 2122 of the circularly keyed lockable socket 2103 collides withthe circular ridge 2529 of the mismatched circularly keyed lockable lowprofile sheath 2501, if engagement of these two components wereattempted.

Also provided are electrical connector assemblies that include a sealextending around a stud assembly in a module interior. In certainembodiments, the stud assembly includes a flange portion extendingaround the base of a conductive cylinder portion of the stud. A sealdisposed between the flange and the module glass is formed by coatingthe flange with a sealant material. An example is shown in FIG. 29,which shows a cross-sectional view of an electrical connector assemblyfor a photovoltaic module 2905. A conductive stud assembly 2902 includesa base portion 2932 extending around the stud assembly 2902. A seal 31is disposed between base portion 2932 and outer layer 2933 of thephotovoltaic module 2905. While some weather-proofing is provided by aseal 2934 disposed between the circularly keyed lockable low profilesheath 2901 and the outer layer 2933 of the photovoltaic module 2905,the inclusion of a seal 2931 between the base portion 2932 of theconductive stud assembly 2902 and the outer layer 2933 of thephotovoltaic module 2905 provides additional protection to internalportions of the photovoltaic module in adverse weather conditions. Theseal may comprise a material that acts as a desiccant to prevent waterfrom entering the interior of the module, for example a zeolite.Examples of seal materials that may be used include butyl rubber andsilicone. The seal may also be relatively thick compared to thethickness if the base portion 2932 of the stud assembly 2902. Examplethickness of the seal range from about 0.5 to 5 mm.

Although the foregoing invention has been described in some detail forpurposes of clarity of understanding, it will be apparent that certainchanges and modifications may be practiced within the scope of theinvention. For example, while certain embodiments described above havecircular studs, sockets and sheaths, other shapes may be used. Incertain embodiments, a circularly keyed socket and sheath may beemployed, with the base portions of either of those components shaped asdesired. Also, in certain embodiments, the designs may be modified suchthat a socket member connects to any type of cable or other interconnectmember for interconnection between modules. While various types ofinter-engageable keyed and/or locking features have been describedabove, the invention is not so limited and may use any type ofinter-engageble features as recognized in the art. The variousconduction paths described may also be altered without departing fromthe scope of the invention. There are many alternative ways ofimplementing the apparatuses of the present invention. Accordingly, thepresent embodiments are to be considered as illustrative and notrestrictive, and the invention is not to be limited to the details givenherein.

1. A low-profile electrical connector assembly for a solar module,comprising: a conductive member comprising a conductive base portion andan axially-oriented cylindrical portion having first and second endswith a insulative portion at the second end and a conductive portionextending from the insulative portion to the first end; a toroidalsheath member positioned substantially co-axially about said cylindricalportion to surround at least the conductive portion thereof; and asocket member comprising a base portion and a hollow conductivecylindrical member extending from the base portion and configured tomate with a conductive portion of the conductive member, wherein saidtoroidal sheath member and said socket member comprise keyedinter-engageable features.
 2. The electrical connector assembly of claim1 wherein the profile of the mated conductive toroidal sheath and socketmember is no more than about 1.5 inches.
 3. The electrical connectorassembly of claim 1 wherein the cylindrical portion of the conductivemember is no more than about 0.5 inches long.
 4. The electricalconnector assembly of claim 1 wherein the keyed features of the toroidalsheath member form a circle and wherein the keyed features of the socketmember form a circle.
 5. The electrical connector assembly of claim 4wherein keyed features of the toroidal sheath member are engageable withthe keyed features of the socket member in any rotational position ofthe socket member in a plane parallel to a surface of the solar module.6. The electrical connector assembly of claim 1 wherein the keyedinter-engageable features comprise a circular groove and a raisedcircular ridge configured to fit into said groove.
 7. The electricalconnector assembly of claim 1 wherein the keyed features of one of thetoroidal sheath member and the socket member comprise one or more rimmedlocking portions; further wherein the keyed features of the other of thetoroidal sheath member and the socket member comprise ridged lockaccepting portions configured to engage the rimmed locking portionsmembers.
 8. The electrical connector assembly of claim 1 wherein thekeyed features of one of the toroidal sheath member and the socketmember comprise one or more flexibly resilient members; further whereinthe keyed features of the other of the toroidal sheath member and thesocket member comprise substantially inflexible locking membersconfigured to engage the flexibly resilient members.
 9. The electricalconnector assembly of claim 7 wherein, when the keyed inter-engageablefeatures of the toroidal sheath member and the socket member areengaged, the connector is locked.
 10. The electrical connector assemblyof claim 8 wherein the keyed inter-engageable features comprise anaperture for accepting a tool configured to unlock the connector. 11.The electrical connector assembly of claim 1 wherein the keyedinter-engageable features comprise at least one slot and at least oneprong configured to fit into the at least one slot.
 12. The electricalconnector assembly of claim 1 wherein said toroidal sheath member andsaid socket member comprise lockable inter-engageable features.
 13. Theelectrical connector assembly of claim 12 wherein the lockable featuresof one of the toroidal sheath member and the socket member comprise oneor more rimmed locking portions; further wherein the lockable featuresof the other of the toroidal sheath member and the socket membercomprise ridged lock accepting portions configured to engage the rimmedlocking portions members.
 14. The electrical connector assembly of claim12 wherein the lockable features of one of the toroidal sheath memberand the socket member comprise one or more flexibly resilient members;further wherein the lockable features of the other of the toroidalsheath member and the socket member comprise substantially inflexiblelocking members configured to engage the flexibly resilient members. 15.The electrical connector assembly of claim 1 wherein the conductivemember extends through an outer layer of the module, and furthercomprising a seal on the interior of the module disposed between theconductive base portion of the conductive member and the outer layer.16. An electrical connector assembly for a solar module, comprising: aconductive member comprising an axially-oriented cylindrical portionhaving first and second ends; a sheath member positioned about saidcylindrical portion to surround at least the conductive portion thereof;and a socket member comprising a base portion, a conductive memberengaging portion configured to mate with the cylindrical portion of theconductive member; wherein the socket member is not engaged with theconductive member, the sheath member surrounds at least the conductiveportion of the conductive member such that the electrical connectorassembly is finger safe.
 17. The electrical connector assembly of claim16 wherein the sheath member comprises: an outer wall, the outer wallcomprising a front face, the front face comprising two opposing portionsextending inward and sized to allow a connector to fit between the twoopposing portions; a front face opening in the outer wall; and a ceilingportion having a ceiling opening.
 18. The electrical connector assemblyof claim 17 wherein the ceiling opening is in communication with frontface opening.
 19. The electrical connector assembly of claim 17 whereinthe ceiling opening is defined by the ceiling portion and is not incommunication with the front face opening.
 20. The electrical connectorassembly of claim 16 wherein the socket member comprises a base portionhaving a hollow cylindrical stud-receiving area formed therein.
 21. Theelectrical connector assembly of claim 16 wherein the socket memberfurther comprises a vertical nubbin extending from the circular baseportion.
 22. The electrical connector assembly of claim 16 wherein thesheath member comprises a side wall having a rim and connected to abase, wherein the base comprises a base opening and wherein the diameterof the portion of the side wall that connects to the base is larger thanthe diameter of the rim.
 23. The electrical connector assembly of claim16 wherein the cylindrical portion of the conductive member is flared atone end.
 24. A solar module comprising: first and second encasinglayers; a plurality of interconnected solar cells disposed between thefirst and second encasing layers; a first external connector assemblycomprising a first stud member extending through an encasing layer andelectrically connected to the plurality of interconnected solar cellsand a first keyed sheath member disposed on the encasing layer andsurrounding at least a conductive portion of the first stud member,wherein said first keyed sheath member is configured to mate with afirst keyed socket member; and a second external connector assemblycomprising a second stud member extending through an encasing layer andelectrically connected to the plurality of interconnected solar cellsand a second keyed sheath member disposed on the encasing layer andsurrounding at least a conductive portion of the second stud member,wherein said second keyed sheath member is configured to mate with asecond keyed socket member; wherein the first keyed sheath member isconfigured such that it cannot mate with the second keyed socket member,and further wherein the second keyed sheath member is configured suchthat it cannot mate with the first keyed socket member.